Spa side wall insulated jacket and method of use

ABSTRACT

An insulated jacket for an un-insulated spa has at least one insulating material that is enclosed by a cover. The cover has top and bottom ends and two free side ends. The cover includes means for securing the ends together when the cover surrounds the side wall of the spa to form a continuous periphery. The cover insulates against heat loss for heated water contained in the spa.

This application claims priority under 35 USC 119(e) based on application Ser. No. 61/266,735, filed on Dec. 4, 2009.

FIELD OF THE INVENTION

The invention relates to an insulated jacket adapted to cover a hot tub, particularly a hot tub that lacks insulation surrounding the spa body.

BACKGROUND OF INVENTION

In the world of outdoor hot tubs and spas, people enjoy an invigorating hot bubbly baths which help relax and de-stress our bodies. The common 7×7 or 8×8 style of tub is a molded acrylic tub designed to hold 2-20 people depending on the size. Normally, these tubs are encapsulated in a 2×2 synthetic or wood frame with a 2×4 bottom in which a molded acrylic and fiberglass tub sits into. The water is then filled into the molded tub and a heater, which is regulated by the owner for intensity, heats the water to a preferred temperature through a maze of jets and hoses. A typical temperature for the water is around 102° F.

In the prior art, it is well known to insulate a spa by surrounding the spa body with an insulation. Often, the insulation is a foam insulation that is sprayed around the spa body. The insulation is then surrounded by the spa side wall. The sides of the tub have also been enclosed with a reflective insulation, and this insulation is then surrounded by the side wall, which is made from a plastic or wood.

Spas also employ covers that are typically made of a vinyl-covered foam material to keep the water in the spa from losing much heat. These vinyl materials are marine grade UV protected, so that they have sufficient durability when outside for long periods of time.

The spa industry has also concentrated on developing the look of the spa in terms of side wall materials, colors, textures and the like. These side wall features are significant parts of the overall spa design and are clearly a selling point from the purchaser's standpoint.

One problem with spas is that many of the less expensive spas are manufactured without insulation or the minimum insulation, e.g., reflective material surrounding the spa body. Consequently, these spas, which could amount to almost 60% of the total spas being made, are highly inefficient when it comes to heating and maintaining the spa water at temperature and the costs for operating such a spa when outside a building or other enclosure are quite high. Therefore, there is a need for improvements in the field of spas. The present invention responds to this need by providing an insulated jacket designed to surround the side walls of a spa and provide a high degree of insulation.

SUMMARY OF THE INVENTION

The present invention provides an insulated jacket designed to surround the side walls of a spa to provide insulation and reduce the heat losses and operating costs.

Another aspect of the invention is a method of covering the side walls of a spa to reduce heat loss during spa operation and/or enhance the look of the spa.

More particularly, and in one embodiment, the invention comprises an insulated jacket adapted to surround side walls of a spa, particularly a spa that is not insulated around the spa tub. The insulated jacket includes an insulation material and a cover enclosing the insulation material. The cover is elongated in shape and has a top end, bottom end and two side ends. Means are provided for securing the cover to a spa to form a continuous outer periphery of the cover surrounding the spa. The cover is sized so that it exposes a top of the spa and surrounds the side wall of spa to provide insulation to minimize heat loss through the side walls of the spa.

The insulated jacket can use a variety of insulating materials such as a fiberglass blanket or bat, preferably R-13 to up to R-20, a loose fill of insulating material, a sprayable foam, a reflective insulation, and the like.

The cover can be any material such as a polymer material, e.g., a vinyl, more preferably a marine quality vinyl with UV protection.

The securing means can be at least one belt, with the at least one belt attached to the cover along a periphery thereof. The belt ends can be attachable to each other for securing the jacket to the spa. The belts ends can be attached using a mechanical attachment. One belt end can have a come-along adapted to receive the other belt end for cinching of the jacket. The securing means can comprise one or more of buttons, snaps, hook and loop fasteners, and rings. The cover can include stitching for decorative purposes and/or insulation retention purposes and/or one or more designs and/or colors to enhance the look of the jacket.

The invention also includes a method of insulating a side wall of a spa, wherein the spa has a spa body surrounded by a side wall. The insulated jacket is placed around the side wall and the ends of the jacket are secured together such that the cover completely surrounds the side wall so that the jacket at least reduces heat loss during operation of the spa.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The features and advantages of the present invention will become more apparent upon consideration of the following detailed description of specific embodiments thereof especially when considered in conjunction with the accompanying drawings where in like parts of each of the several figures are identified by the same reference numerals and where in:

FIG. 1 is a perspective view of one embodiment spa jacket surrounding a spa.

FIG. 2 is a cross sectional view of the spa jacket, a spa side wall, and spa body.

FIG. 3 shows one embodiment of a means for securing the spa jacket to a spa.

FIG. 3A shows a come-along mechanism schematically for securing the spa jacket.

FIGS. 4A-4E show different alternatives in schematic form for securing the spa jacket to a spa.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Within the hot tub and spa industry, over 85% of the estimated 6.6 million units currently in use in North America are designed with little insulation protecting the side walls. Higher priced units are fully insulated in the under cabinet by the manufacturers installing full expandable foam to fill the under cabinet area with insulation.

As a result of the majority of the non-full foam units not being insulated, the heated air within the cabinet of the unit is only contained by a reflective insulation and a synthetic cabinet. This results in poor energy consumption usage in the colder months and nights of the year. The invention provides improvements in this regard by providing a spa jacket that is adaptable for virtually any type of spa. The jacket adds an R-value that initial testing that can provide a 30%+ energy savings depending on the position and type of unit tested.

Besides providing an advantage in terms of insulation, the spa jacket can be used in individualize a spa and/or increase its esthetic appeal of a large piece of outdoor furniture by adding preferred colors, logos and/or teams around the tubs.

In one embodiment, the jacket can be custom made to a predetermined size for a given spa. The jacket utilizes an R-13 or R-20 custom cut fiberglass insulation that is enclosed or encapsulated in a cover, e.g., a plastic vapor barrier, which is sewn into an individualized custom made spa jacket. In one mode, the spa jacket can be attached to the hot tub or spa by incorporating into the jacket, a belt which is tightened manually by a leverage come-along unit and secured with two interlocking snaps. The spa jacket is sized so that it leaves the top of the spa exposed so as not to interfere with the spa top cover, which is designed to insulate the water from the top and to keep debris from entering the spa.

Referring now to FIGS. 1 and 2, one embodiment of a spa jacket is designated by the reference numeral 10 and shown surrounding the side wall 21 of a spa 20. The spa jacket 10 has a cover 1 that surrounds insulation 3. The cover is shown as two parts 1 b and 1 c, each joined at seam 6. Of course, the cover could use only one seam if so desired. The cover 1 also has a belt loop 5, which assists in securing the cover to the spa 20. Also, the seam could be formed by stitching, adhesive or other type of bonding between the attached edge or a combination of more than one type of connecting means. The cover can also employ stitching 4 along a length thereof. The stitching 4 is shown vertically but stitching can be formed horizontally or at an angle if so desired. The stitching can provide a decorative aspect and/or hold the insulation material 3 in place so that it remains in place between the cover to provide an effective insulating affect along the height of the side wall 21.

FIG. 1 also shows un-insulated space 23 between the side wall 21 and the spa body 25. The presence of the spa jacket insulates the spa so that less energy is needed to keep the water 27 in the spa body 25 at the desired temperature.

The spa jacket is also equipped with a means for securing the cover to a spa. FIGS. 3 and 3A show one embodiment of a securing means. The cover 1 has a top end 7, a bottom end 9, and side ends 11 and 13. The cover is sized so that the side ends 11 and 13 overlap so that a continuous outer periphery is formed when the cover is in place. A belt 17 is provided that runs in the belt loop 5, with the belt having ends 19 and 22. Figure designates the means for linking the belt ends together by reference numeral 15 and this represents any means that could pull the belt ends to cinch the jacket around the spa. One embodiment of such a securing means is a come-along 24 shown in FIG. 3A. This type of a mechanism can be employed to cinch the belt 17 around the spa and secure the cover in place. Come-alongs are well known in the art and it is schematically depicted in FIG. 3A with one end 32 secured to belt end 19 and the belt end 22 shown engaged in the come-along ratchet mechanism so that moving the come-along lever 26 can cinch the jacket around the spa side walls 21. It should be understood that FIG. 3 depicts the side of the cover facing the spa side wall 21 so that the securing means is not visible when the jacket is in place. However, the securing means could be designed on the outside of the cover as well, see below where buttons or a zipper would be used.

While a come-along belt assembly is disclosed as one means to secure the cover to the spa, other means could also be used. For example, two belts could be used, the other one arranged close to the bottom end. Each of the two belts could include a come-along mechanism on one end thereof. Hook and loop fasteners could be used, with one end having one of more segments of hooks and the other having the corresponding segments with the loops.

Referring to FIGS. 4A-4E, other options for securing the spa jacket to the spa include:

-   -   1. Rings 30 on one end 31 of the cover, which link to straps 33         on the other end 35 of the cover, see FIG. 4A, for cinching. In         this embodiment, the straps and rings would be to be firmly         reinforced so that any cinching of the spa jacket would not         compromise the integrity of the cover, e.g., tear it and expose         the insulation.     -   2. A zipper assembly 40 can be employed with one side 41         attached to the spa side wall 21 by fasteners 45 with the other         side 43 sewn or otherwise attached to the top of the cover 1,         see FIG. 4B. The zipper could also be made part of the jacket         such that the two ends 31 and 35 could be zippered together to         secure the jacket to the spa.     -   3. Snaps 50 can be used, with one part attached to end 31 of the         cover and the other part attached to the other end 35, see FIG.         4C. As an alternative, buttons could be used, with one end 31         holding the buttons and the other end 35 having the button         holes.     -   4. Roping 60 can be used, where the roping is threaded through         the spa jacket and both ends are tied off at 61, see FIG. 4D.     -   5. A hook and loop fastening system 70 is shown in FIG. 4E,         wherein end 31 and end 35 are joined by engaged hooks 71 and         loops 73.

The spa jacket can be tailored to each brand and type of tub in the market, providing an added insulation value by reducing the energy consumption by an average 30%. The spa jacket can also provides an esthetic value to the unit by the user selecting the color, type and sewing patterns to individualize their spa jacket. The custom spa jacket is designed to decrease the energy consumption of the hot tub or spa by adding R-value insulation to hold in the heat within the under cabinet of the unit. The spa jacket also protects the exterior from wind, snow and cold while increasing the look and individualizing each and every unit purchased. The spa jacket can also cover a side wall that is already worn or damaged due to exposure to the environment. In this way, the worn side wall is covered and the spa has an improved outward appearance.

The spa jacket can also be made with indicia based on a user's desires. For example, the spa jacket can display sport teams colors, logos, design or the like. Different colors or patterns can be employed as part of the cover so that the cover blends or complements structures or the like that would be in the vicinity of the spa.

While the insulation is described in one embodiment as ranging from R-13 to R-20, other R factors could be used depending on where the spa is actually located. Higher or lower R values may be desirable depending on the particular spa location.

The insulation is preferably a fiberglass blanket or batt insulation since it makes the jacket easily configured when being installed. This fiberglass insulation is similar to that employed wall construction, and comprises a layer of insulation that includes a vapor barrier polyethylene or other material sheet to encompass the insulation. In the jacket, the insulation easily wraps around the spa, whether it be square, rectangular, other polygonal, circular, oval, and the like. Of course, other flexible insulations could also be used such as: a precut reflective insulation; a loose fill insulation such as feather, glass, wool, cotton sponge, or the like; bat and blanket insulation; a sprayable foam type, which could be applied onto the vinyl cover material and then the cover material could be configured/closed up to encapsulate the foam. Different types of insulation materials could be combined as well depending on the environment for the spa jacket.

The cover for the jacket should be made of a material that will stand up to the elements since it will be outside for an extended period of time. A preferred material is a marine grade UV protected vinyl material such as that used for the spa top covers. The material can have different thickness, with a range of 10-50 mm, with a more preferred range of 20-40 mm, and a target of around 30 mm.

The jacket can be made in a number of different modes as follows.

-   -   Base spa jacket         -   Typically a standard R13 valued insulation with a vinyl wrap             which comes in selected base colors which will wrap a 7×7 or             8×8 tubs. This unit can be made available through big box             outlets and sold to the base tub customer.     -   Custom spa jacket

A custom jacket, consist of a R13-R20 valued insulation special made to order blanket, which accommodates more custom tubs of differing sizes and requirements. The selection of colors and materials allows the purchaser to accommodate external radio and CD pockets as well as non-standard shapes and sizes.

-   -   Premium custom spa jacket

A premium custom jacket, consist of a R13-R20 valued insulation special made to order blanket, which accommodates more custom tubs of differing sizes and requirements. The additional features of the premium line include two tone and school coloring e.g. University of Michigan blankets etc.

The invention has a number of advantages over the prior art designs such as:

-   -   low cost with maximum savings;     -   base tubs can now have 4 season operation;     -   esthetically appealing—increases visual appearance;     -   customization allows for perfect fit;     -   easy installation and cleaning; and     -   transforms old tubs into appealing yard furniture. 

1. An insulated jacket adapted to surround sides walls of a spa comprising: a) an insulation material; b) a cover enclosing the insulation material, the cover being elongated in shape, and having a top end, bottom end and two side ends, c) means for securing the cover to a spa to form a continuous outer periphery of the cover surrounding the spa, d) wherein the cover is sized so that it exposes a top of the spa and surrounds the side wall of spa to provide insulation to minimize heat loss through the side walls of the spa.
 2. The insulated jacket of claim 1, wherein the insulation material is one or more of a fiberglass blanket or batt, preferably R-13 to up to R-20, a loose fill of insulating material, a sprayable foam, and a reflective insulation.
 3. The insulated jacket of claim 1, wherein the cover is a polymer material such a vinyl, more preferably a marine quality vinyl with UV protection.
 4. The insulated jacket of claim 1, wherein the securing means further comprises at least one belt, the at least one belt attached to the cover along a periphery thereof, the belt ends attachable to each other for securing the jacket to the spa.
 5. The insulated jacket of claim 4, wherein the belts ends are attached using a mechanical attachment.
 6. The insulated jacket of claim 5, wherein one belt end has a come-along adapted to receive the other belt end for cinching of the jacket.
 7. The insulated jacket of claim 1, wherein the securing means comprises one or more of buttons, snaps, hook and loop fasteners, and rings.
 8. The insulated jacket of claim 1, wherein the cover includes stitching for decorative purposes and/or insulation retention purposes.
 9. The insulated jacket of claim 1, wherein the cover includes one or more designs and/or colors to enhance the look of the jacket.
 10. A method of insulating a side wall of a spa comprising: a) providing a spa having a spa body surrounded by a side wall; b) placing the insulated jacket of claim 1 around the side wall and securing the ends of the jacket together such that the cover completely surrounds the side wall so that the jacket at least reduces heat loss during operation of the spa. 